PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW SOFTWARE AND CERTAIN HARDWARE COMPONENTS ON CERTAIN 24M MOTOR GRADERS
Usage:
REBE6399-01
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| 28Oct2010 |
| (Revised 09Dec2010) |
U-438
A-358
D-381
O-381
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| Safety Parts stock action needed | PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW SOFTWARE AND CERTAIN HARDWARE COMPONENTS ON CERTAIN 24M MOTOR GRADERS |
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| 7610 7620 7601 7332 4307 5051 1130 1902 4322 | PI10825 |
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| NOTE: | This Program must be administered as soon as possible.
When reporting the repair, use "PI10825" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim
Description Code and "T" as the SIMS Description Code.
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| NOTE: | When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code. |
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| NOTE: | This Revised Service Letter replaces the 28Oct2010 Service Letter. Changes have been made to the Action Required Section. |
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PROBLEM
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| The ripper handle switch needs to be replaced on certain 24M Motor Graders. The existing switch may fail causing uncommanded movement of the ripper function. The actuator valve group (Primary Steering Control Module) needs to be inspected on certain 24M Motor Graders. The existing actuator valve group may cause excessive steering system codes to be generated. The above failures, in conjunction with other factors or circumstances, could result in a risk of personal injury or death. New software needs to be installed on certain 24M Motor Graders. Software improvements are listed below. Messenger: -Update E875 "Low System Voltage" from a level 3 to a level 2 event -Updated languages -Update to reduce the frequency of 811-09 Diagnostic Codes at machine startup -Addition of an E490-1 "Park Brake Applied While Shift Lever Not in Neutral" event -Addition of an E562-2 "Steering Lever Has Not Been Aligned To Wheel Steering Angle" Event Implement: -Reduced the debounce time for the Neutral Articulation switch from 100ms to 50ms to allow the selection to be made easier. -Alignment of the left hand joystick to the steering axle when the machine is started has been improved. -The display for the steering oil temperature will no longer display **** when the temperature of the steering oil is above 60 deg C or below -50 deg C. -Remove invalid 2202-12 "Primary Steering Control Module Failure" at machine start up. -When an E256-3 "Steering in the Wrong Direction" or an E257-3 "Steering With No Command" occurs while in secondary steering (Trans/Chassis ECM), the secondary steering hydraulic valves will remain active. -Correct the issue with configuring cylinder trim file parameters manually through Cat ET. -Revised the hydraulic oil viscosity parameters for hydraulic cold mode that trigger the Level 1 and Level 2 "Gear Too High" events. -Detection and indication of event code E263 (Low Main Pump Pressure) has been improved under certain machine operating conditions. Transmission: -Improved the park brake release strategy to eliminate the possibility of driving through the park brake when the machine is put into gear. The change makes it necessary to have the park brake switch disengaged in order for the transmission to be shifted out of NEUTRAL. -Increased the maximum detectable transmission output speed from 5000 rpm to 7000 rpm (Maximum ground speed detected will now peak at 126 kph or 78 mph). Engine: -Throttle lock will be disabled when cycling the throttle lock switch from manual to auto and from auto to manual. -Revised the E172-1 "High Air Filter Restriction" trip level from 6.5 kpa to 7.5 kpa at 15 seconds to correct an issue that causes the air filter restriction light to activate prematurely. -Revised the E172-2 "High Air Filter Restriction" trip level from 6.5 kpa to 7.5 kpa at 30 seconds to correct an issue that causes the air filter restriction light to activate prematurely. |
AFFECTED PRODUCT
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| Model | Identification Number |
| *******Group 1******* | |
| 24M | B9K00363-00389 |
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| *******Group 2******* | |
| 24M | B9K00250-00323 |
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| *******Group 3******* | |
| 24M | B9K00242-00249, 324-362 |
PARTS NEEDED
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Qty |
Part Number | Description |
| *******Group 1******* | ||
| 1 | 5P7958 | SLEEVE-CA SPLICE |
| 1 | 3635774 | Implement #1 Software |
| 1 | 3635776 | Transmission/Chassis Software |
| 1 | 3666155 | 24M Engine Software |
| 1 | 3667546 | Implement #2/#3 Software |
| 1 | 3697880 | Messenger Software |
| 1 | 3697882 | Messenger Software |
| 1 | 3697884 | Messenger Software |
| 1 | 3697886 | Messenger Software |
| 1 | 3697888 | Messenger Software |
| 1 | S_B_7990 | Operation and Maintenance Manual (24M) |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer. | ||
| *******Group 2******* | ||
| 1 | 5P7958 | SLEEVE-CA SPLICE |
| 1 | 3584931 | SWITCH AS-RPR |
| 1 | 3635774 | Implement #1 Software |
| 1 | 3635776 | Transmission/Chassis Software |
| 1 | 3655978 | KIT-ACTUATOR (If Required After Inspection) |
| 1 | 3666155 | 24M Engine Software |
| 1 | 3667546 | Implement #2/#3 Software |
| 1 | 3697880 | Messenger Software |
| 1 | 3697882 | Messenger Software |
| 1 | 3697884 | Messenger Software |
| 1 | 3697886 | Messenger Software |
| 1 | 3697888 | Messenger Software |
| 1 | S_B_7990 | Operation and Maintenance Manual (24M) |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer. | ||
| *******Group 3******* | ||
| 1 | 5P7958 | SLEEVE-CA SPLICE |
| 1 | 3635774 | Implement #1 Software |
| 1 | 3635776 | Transmission/Chassis Software |
| 1 | 3655978 | KIT-ACTUATOR (If Required After Inspection) |
| 1 | 3666155 | 24M Engine Software |
| 1 | 3667546 | Implement #2/#3 Software |
| 1 | 3697880 | Messenger Software |
| 1 | 3697882 | Messenger Software |
| 1 | 3697884 | Messenger Software |
| 1 | 3697886 | Messenger Software |
| 1 | 3697888 | Messenger Software |
| 1 | S_B_7990 | Operation and Maintenance Manual (24M) |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer. | ||
ACTION REQUIRED
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Remove all 308-0938 Actuator Valve Groups with a date code of 0210C or earlier from dealer parts stock. Refer to Image 1 for date code information. |
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| Image1 |
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| A new Operation and Maintenance Manual will be provided after completion of this service letter. Order the new Operation and Maintenance Manual from the following list according to your machine model and serial number in the language needed: Order version -08 or later of the following media: English - SEBU7990 Portuguese - SPBU7990 Spanish - SSBU7990 Chinese ? SCBU7990 Turkish - STBU7990 Romanian - S9BR7990 Russian - SRBU7990 Remove the 5P7958 Sleeve-Ca Splice from the lanyard that secures the O&MM in the cab. Secure the new O&MM to the lanyard using a 5P7958 Sleeve-Ca Splice or equivalent. Prior to releasing the machine back into service place a printed copy of Service Magazine "New Software That Affects Machine Operation is Now Used on Certain Motor Graders" on the seat of the cab. In the case that the Actuator Valve Group (Steering Control Module) is being changed, please ensure that when the valve is removed, the resolver (as shown in image 1 as number 7) is not removed with the actuator valve group. This part should remain with the main portion of the steering valve. The result of the resolver being removed from the system would be slow or no steering to the left which could potentially cause E258 events to be generated. |
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 |
| Image1 |
OWNER NOTIFICATION
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| U.S. and Canadian owners will receive the attached Owner Notification. |
SERVICE CLAIM ALLOWANCES
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|
Submit one claim for all parts removed from dealer parts stock. |
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| NOTE: This is a 2.0-hour job for Group 1 | |||||
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| NOTE: This is a 4.5-hour job for Group 2 | |||||
| Include the 11 digit date code for the actuator valve group in the first line of the service claim comments. |
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| NOTE: This is a 4.0-hour job for Group 3 | |||||
| Include the 11 digit date code for the actuator valve group in the first line of the service claim comments. |
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PARTS DISPOSITION
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| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
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| ***** NACD ***** Hold all 308-0938 Actuator Valve Groups with date codes between 3308A and 0210C for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. Handle all other parts in accordance with your warranty bulletin on warranty parts handling. ***** EAME, LACD, and APD ***** Hold all 308-0938 Actuator Valve Groups for 30 days for a possible Parts Return Request (PRR). When returning the part, please label it with a blue warranty tag. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling. Handle all other parts in accordance with your warranty bulletin on warranty parts handling. |
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| COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS XYZ Corporation 3240 Arrow Drive Anywhere, YZ 99999 SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW SOFTWARE AND CERTAIN HARDWARE COMPONENTS ON CERTAIN 24M MOTOR GRADERS MODELS INVOLVED - 24M Motor Graders Dear Caterpillar Product Owner: The Ripper handle switch/switches need to be replaced on certain 24M motor graders. The existing switch may fail causing uncommanded movement of the ripper or auxiliary function. The Valve Gp-Actuator (Primary Steering Control Module) needs to be inspected on certain 24M Motor Graders. The existing Valve Gp-Actuator may cause excessive steering system codes to be generated. Failure to apply the above changes may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. A new Operation and Maintenance Manual will also be provided. Updates to the Operation and Maintenance Manual Sections include the following: Safety Section -Park Brake Override Procedure Operation Section -Blade Lift Modulation -Transmission Under Speed Protection Strategy -Optional Warm-Up Procedure for the Hydraulic Oil with Blade Float -Steering Oil Temperature Monitoring System Maintenance Section -Tandem oil and Hydraulic Oil parameters in Lubricant Viscosities Chart There may be other updates to your Operation and Maintenance Manual depending on the revision of Manual that is currently in the machine. Please review the Sections listed above for detailed updates and review the entire Manual for other updates. You will not be charged for the service performed. Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated 28Oct2010 when scheduling this service. We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction. Caterpillar Inc. Identification #(s) Attached to 28Oct2010 Service Letter |
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| Group Number 1 |
| 1. Use Cat Electronic Technician service tool to perform the following work: - Flash Implement #1 ECM with 363-5774 Flash File. - Flash Implement #2 and Implement #3 ECM (if applicable) with 366-7546 Flash File. - Flash the Transmission/Chassis ECM with 363-5776 Flash File. - Flash 24M Engine ECM with 366-6155 Flash File. - Flash the Messenger Monitor Display with the flash file containing the appropriate languages. Reference the following list for the appropriate part number: 369-7880 Software-Monitor (English, Portuguese, Spanish, French, German, Dutch). 369-7882 Software-Monitor (English, Portuguese, Danish, Finnish, Swedish, Norwegian). 369-7884 Software-Monitor (English, Portuguese, Italian, Greek, Hebrew, Turkish). 369-7886 Software-Monitor (English, Portuguese, Russian, Arabic, Chinese). 369-7888 Software-Monitor (English, Portuguese, Romanian, Slovenian, Indonesian). NOTE: New machine flash files are released periodically. Ensure you are using the latest flash files by downloading the files from SISWeb. NOTE: The Transmission/Chassis, Implement #1, #2, and #3 can be flashed over the J1939 Data Link. The Messenger ECM is flashed over CDL. |
| 2. On both the right and left hand steering cylinders, locate the sensor set screw hole (1) and clean out any debris. Tighten the 8T-5070 Set Screw (2) to a torque of 25 +/- 3 Nm. Fill the set screw hole with Loctite 515 or equivalent. |
 |
| Image1.2.1 |
| Group Number 2 |
| Inspect the actuator valve group (Steering Control Module) (1) for the date code. The date code format is as follows: The first 2 numbers refer to the week which the module was built (A), the second two numbers refer to the year (B). The letter following the numbers refers to the day of the week (C) and the last six numbers is the serial number (D). |
| If the date code is 0210C (Week 2 of 2010, Wednesday) or earlier, remove and replace the actuator valve group (Steering Control Module) ensuring the new valve has a date code of 0210D (Week 2 of 2010, Thursday) or newer. Record the 11-digit date code for the valve on the work order so that it can be entered into the comment section of the warranty claim. Reinstall the right hand valve cover. If the date code is 0210D or later, reinstall the right hand valve cover and proceed with flashing the new software as described below: Use Cat Electronic Technician service tool to perform the following work: - Flash Implement #1 ECM with 363-5774 Flash File. - Flash Implement #2 and Implement #3 ECM (if applicable) with 366-7546 Flash File. - Flash the Transmission/Chassis ECM with 363-5776 Flash File. - Flash 24M Engine ECM with 366-6155 Flash File. - Flash the Messenger Monitor Display with the flash file containing the appropriate languages. Reference the following list for the appropriate part number: 369-7880 Software-Monitor (English, Portuguese, Spanish, French, German, Dutch). 369-7882 Software-Monitor (English, Portuguese, Danish, Finnish, Swedish, Norwegian). 369-7884 Software-Monitor (English, Portuguese, Italian, Greek, Hebrew, Turkish). 369-7886 Software-Monitor (English, Portuguese, Russian, Arabic, Chinese). 369-7888 Software-Monitor (English, Portuguese, Romanian, Slovenian, Indonesian). NOTE: New machine flash files are released periodically. Ensure you are using the latest flash files by downloading the files from SISWeb. NOTE: The Transmission/Chassis, Implement #1, #2, and #3 can be flashed over the J1939 Data Link. The Messenger ECM is flashed over CDL. |
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| Image2.2.1 |
| 3. Remove and replace the switch in the ripper handle. The switch does not have float capability and should be replaced with 358-4931 Switch As-Rpr. |
| 4. On both the right and left hand steering cylinders, locate the sensor set screw hole (1) and clean out any debris. Tighten the 8T-5070 Set Screw (2) to a torque of 25 +/- 3 Nm. Fill the set screw hole with Loctite 515 or equivalent. |
| Group Number 3 |
| Inspect the actuator valve group (Steering Control Module) (1) for the date code. The date code format is as follows: The first 2 numbers refer to the week which the module was built (A), the second two numbers refer to the year (B). The letter following the numbers refers to the day of the week (C) and the last six numbers is the serial number (D). |
| If the date code is 0210C (Week 2 of 2010, Wednesday) or earlier, remove and replace the actuator valve group (Steering Control Module) ensuring the new valve has a date code of 0210D (Week 2 of 2010, Thursday) or newer. Record the 11-digit date code for the valve on the work order so that it can be entered into the comment section of the warranty claim. Reinstall the right hand valve cover. If the date code is 0210D or later, reinstall the right hand valve cover and proceed with flashing the new software as described below: Use Cat Electronic Technician service tool to perform the following work: - Flash Implement #1 ECM with 363-5774 Flash File. - Flash Implement #2 and Implement #3 ECM (if applicable) with 366-7546 Flash File. - Flash the Transmission/Chassis ECM with 363-5776 Flash File. - Flash 24M Engine ECM with 366-6155 Flash File. - Flash the Messenger Monitor Display with the flash file containing the appropriate languages. Reference the following list for the appropriate part number: 369-7880 Software-Monitor (English, Portuguese, Spanish, French, German, Dutch). 369-7882 Software-Monitor (English, Portuguese, Danish, Finnish, Swedish, Norwegian). 369-7884 Software-Monitor (English, Portuguese, Italian, Greek, Hebrew, Turkish). 369-7886 Software-Monitor (English, Portuguese, Russian, Arabic, Chinese). 369-7888 Software-Monitor (English, Portuguese, Romanian, Slovenian, Indonesian). NOTE: New machine flash files are released periodically. Ensure you are using the latest flash files by downloading the files from SISWeb. NOTE: The Transmission/Chassis, Implement #1, #2, and #3 can be flashed over the J1939 Data Link. The Messenger ECM is flashed over CDL. |
 |
| Image3.2.1 |
| 2. On both the right and left hand steering cylinders, locate the sensor set screw hole (1) and clean out any debris. Tighten the 8T-5070 set screw (2) to a torque of 25 +/- 3 Nm. Fill the set screw hole with Loctite 515 or equivalent. |
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